11/15/02H.J. Krebs IFR Improvement Phase II (Barrel) Mechanical Engineering Issues H. James Krebs November 15, 2002

11/15/02H.J. Krebs Scope of Work Under Investigation Remove 18 layers of RPCs Install 7/8” thick brass in slots previously occupied by layers 3,4,6,7,9,10,12,13,15 & 16 – 10 layers (8.75” thickness) Install detectors (technology TBD) in layers 2,5,8,11,14,16,17 & 18 – 8 layers

11/15/02H.J. Krebs Modifcation of Detector Loading DescriptionWeight (tons) FWD Brass30 Fwd Steel28 FWD Belt Chambers3 FWD Counterweights-24 Barrel Brass113 Total150

11/15/02H.J. Krebs Present EQ Committee Approval IFR Improvement Phase I (FWD End Doors) –Add 1” thick layers of brass in door slots 8,10,12,14 & 16 (30 tons) –Add 28 tons of steel absorber on fwd end of doors –Add 3 tons of belt chambers around end door periphery –Remove one counterweight from each door skid (-24 tons) IFR Improvement Phase II (Barrel) –Add 7/8” thick layers of brass in barrel slots 7,9,11,13 & 15 (60 tons) EQ Committee approval on

11/15/02H.J. Krebs Earthquake Issues for New Scope Calculate new CGs and determine extent of loading asymmetries Differential motion between detector and floor slab – cannot exceed 8.5” –Re-do isolator analysis Strength of floor slab Strength of X & Z restraint rods and connections to floor and barrel Connection of Y restraint to floor Structural analysis of barrel system –Redo “Missing Bolts Analysis”

11/15/02H.J. Krebs Chamber Removal Issues (General) At present, the mechanical scope of work does NOT include removal and replacement of layers 1, 19 and the cylindrical RPC RPC extraction and replacement detector installation shall occur on forward end Probably committed to whole sextant when starting –Removal of any chamber in a sextant will likely damage other chambers in that sextant due to the bundling of gas lines and HV cables on backward end Rigid installation work platforms will be needed –Modify end door work platforms?

11/15/02H.J. Krebs Chamber Removal Issues (General) Remove fwd end plug for side sextants BL00,BL05,BL03 & BL02 End doors open – fwd & bwd Extend travel of fwd doors Layer No. Side Sextants Add’l Travel Needed End Plug Inst. (mm) Add’l Travel Needed End Plug Removed (mm) 2 thru

11/15/02H.J. Krebs Chamber Removal Issues (General) Load transfer of calorimeter weight needed for side sextants –Removal of F-CAL (still under investigation) –Support from upper barrel EQ support beams Removal of corner plates –Max of 2 plates removed at any time On forward end only –Continuous position monitoring of detector internals as/after corner plates are removed Many dial indicators Layer 18 buried behind flux bars which are buried behind corner plates

11/15/02H.J. Krebs Layer 18, Layer 19, Corner Blocks

11/15/02H.J. Krebs Schedule and Installation Issues Approximately 2 days lost due to photographers, film crews and tours 3 days lost due to PEP survey at end of run 3 days lost due to PEP survey at start of run 3 Days lost due to PPS certification No access to EMC during chamber removal and installation process Tooling to install replacement IFR detectors is probably similar in concept but different than RPC removal tooling

11/15/02H.J. Krebs IFR Sextant BL01 (Top) Work platforms needed Remove IFR cabling Disconnect & remove IFR cooling loops Remove center gap plate Solenoid –Disconnect solenoid axial supports –Remove axial support plate New fixture needed –Release upper radial supports Remove fwd corner plates at 1:00 & 11:00 Layer 1 replacement will be difficult –Support plate is cambered

11/15/02H.J. Krebs IFR Sextant BL00 (Upr East) Work platforms needed Remove fwd corner plates at 1:00 & 3:00 –New fixture needed Remove Gap plates – fwd & bwd Disconnect and peel back cabling –SVT Remove IFR cabling Remove piping –B-CAL N 2 vent –B-CAL chilled water return –DCH fwd end plate cooling supply & return (not used) –VESDA line

11/15/02H.J. Krebs IFR Sextant BL00 (Cont’d) Solenoid –Disconnect solenoid axial supports –Remove axial support plate –Release upper radial supports Remove forward end plug Disconnect fwd east door drive and move door additional 289mm –Remove belt chambers Transfer calorimeter load – east side Layer 1 replacement will be difficult –Support plate is cambered

11/15/02H.J. Krebs Load Transfer

11/15/02H.J. Krebs IFR Sextant BL05 (Lwr East) Remove fwd corner plates at 3:00 & 5:00 –New fixture needed Remove gap plates – fwd & bwd Disconnect and peel back cabling –F-CAL –B-CAL Remove IFR cabling Remove piping –B-CAL N 2 vent- F-CAL Source return –B-CAL H 2 O supply- F-CAL fluorinert supply –F-CAL N 2 Supply- F-CAL fluorinert return –F-CAL Source Supply

11/15/02H.J. Krebs IFR Sextant BL05 (Cont’d) Solenoid –Disconnect solenoid axial supports –Remove axial support plate –Release upper radial supports Remove forward end plug Disconnect fwd east door drive and move door additional 289mm –Remove belt chambers Transfer calorimeter load – east side

11/15/02H.J. Krebs IFR Sextant BL04 (Bottom) Remove fwd corner plates at 5:00 & 7:00 Remove gap plates – fwd & bwd Remove center gap plate –New fixture needed? Remove IFR cabling Disconnect and remove IFR cooling loops Solenoid –Disconnect solenoid axial supports –Remove axial support plate –Release upper radial supports

11/15/02H.J. Krebs IFR Sextant BL04 (Cont’d) Chamber removal easier if fwd PEP raft support pedestal is removed Not enough Z clearance for chambers to be nominal 3740mm in length –Interference with PEP concrete pier –Maximum clearance is 3570mm Good news – layer 18 remains intact at 3340mm Layers 1 thru 17 limit to 3550mm and position to forward end

11/15/02H.J. Krebs IFR Sextants BL02 & BL03 Similar to sextants BL00 & BL05 Disconnect solenoid hall probe Not necessary to remove belt chambers on fwd west end door

11/15/02H.J. Krebs Brass Lyr No.Weight/Sex (lbs)Total Weight (lbs)Cost (K$) Total

11/15/02H.J. Krebs Alternate Materials Interaction Lengths –Fe~17cm –Cu~15cm –Pb~17.1cm –U~10.5cm –W~9.6cm –Pt~8.9cm

11/15/02H.J. Krebs Brass Design Option Layers 3,4,6,7,9,10 equals 62 tons –Would not require EQ Committee approval –Savings of $407K M&S

11/15/02H.J. Krebs Brass Engineering Issues Prefer to install brass after reinstallation of all corner plates Handling fixtures and installation tooling needed

11/15/02H.J. Krebs Engineering Responsibilities Jim Krebs (SLAC) –Project Management –Brass design including installation and handling fixtures –Installation platforms –Miscellaneous handling fixtures Corner plates Solenoid support arms Richard Boyce (SLAC) –RPC removal fixtures –Replacement chamber handling and installation fixtures

11/15/02H.J. Krebs Engineering Responsibilities Les Dittert (Contract) –Earthquake design and analysis Knut Skarpaas VII (Contract) –Calorimeter load transfer –Calorimeter support arm handling fixture Nancy Yu (SLAC) –Finite element analysis

11/15/02H.J. Krebs

11/15/02H.J. Krebs

11/15/02H.J. Krebs EDIA Cost Estimate TypeMan YearsK$/MYrTotal (K$) Engineer71751,225 Designer Eng Ass.1130 Total1,779

11/15/02H.J. Krebs Fabrication and Shop Labor Fab & Testing Shop Labor TypeMan YearsK$/MYrTotal (K$) Tech Support Total360 q Heavy TypeMan YearsK4/MyrTotal (K$) TypeTotal (K$) Heavy Fab50 Alignment10 Rigging10 Total70

11/15/02H.J. Krebs Installation Labor TypeMan YearsK$/MyrTotal (K$) Tech Support Eng Ass Total653

11/15/02H.J. Krebs M&S Costs TypeTotal (K$) Tooling & Supplies50 Brass903 Total953

11/15/02H.J. Krebs Total Costs - Mechanical TypeAmount (K$) EDIA1,779 Fab & Testing360 Shop Labor70 Installation Labor653 Total (FY2002 $)2,862

11/15/02H.J. Krebs Schedule Early drafts from ~1.5 yrs ago: –Top sextant only: ~1.5 months –East diagonals: ~3.3 months (no endcap removal might cut this by a month) –These were very preliminary schedules that need update!